Patent Grant
11643814
The present technology relates generally to flooring applications. More particularly, the present technology relates to flooring applications around or adjacent drains.
Many traditional shower enclosures include a raised threshold, often termed a “curb,” that retains water within the shower until the water can be drained out of the enclosure. While such curbs serve a useful purpose, they can present a barrier to entry for those with mobility challenges. Also, conventional designers often feel constrained by the need to incorporate such structure into bathroom designs, as it is thought that a more open design makes better use of available floor space.
For at least these reasons, so-called “curbless” or “barrier-free” shower designs are increasingly gaining in popularity. While the aesthetic appeal of such showers is understandable, installation of such showers can pose complications. One such problematic area is that a perimeter of the structure necessary to support and drain water from a curbless shower must be level with the surrounding subfloor to ensure that the shower tiles are installed at the same height as the surrounding floor tiles. This often necessitates reconfiguring the conventional subfloor to ensure that the shower tray is properly positioned relative to the surrounding subfloor: that is, that the shower floor slopes downward from an upper surface of the surrounding subfloor toward a drain.
In accordance with one aspect of the technology, a method is provided for supporting a recessed subfloor panel in a lowered position relative to an adjacent, primary subfloor, the primary subfloor including an overhanging portion extending over and being supported from beneath by one or more floor supports defining a bay therebetween. The method can include positioning a spanning brace within a bay between a pair of floor supports with a first end of the spanning brace positioned beneath and at least partially overhung by an overhanging portion of the primary subfloor. The spanning brace can be secured to lateral, vertical sides of the pair of floor supports such that the spanning brace engages and is supported by the lateral, vertical sides. The overhanging portion of the primary subfloor can be supported atop the spanning brace. A recessed subfloor panel can be supported atop the spanning brace adjacent the recessed subfloor panel at a lower elevation than the adjacent, primary subfloor.
In accordance with another aspect of the technology, a flooring installation is provided, including at least two floor supports separated from one another by a span distance, the at least two floor supports each having lateral, vertical side walls between which an opening is defined. A bay can be defined between the at least two floor supports. A primary subfloor can be supported atop and attached to one of the at least two floor supports, the primary subfloor including an overhanging portion overhanging a portion of the bay. A spanning brace can be disposed between the at least two floor supports in the bay, the spanning brace engaging on opposing ends the lateral, vertical side walls of the floor supports, one end of the spanning brace extending beneath and spaced from the overhanging portion of the primary subfloor. A recessed subfloor panel can be supported atop the spanning brace, the recessed subfloor panel being supported at a lower elevation than the overhanging portion of the adjacent, primary subfloor.
Various methods of installing, configuring, using, manufacturing and providing support brackets or braces and associated flooring components are also encompassed by the technology disclosed herein.
The following drawings illustrate exemplary embodiments for carrying out the technology. Like reference numerals refer to like parts in different views or embodiments of the present technology in the drawings.
Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the technology is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the technology as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the technology.
As used herein, the singular forms “a” and “the” can include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a support bracket” can include one or more of such brackets, if the context so dictates.
As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, an object that is “substantially” enclosed is an article that is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend upon the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. As another arbitrary example, a composition that is “substantially free of” an ingredient or element may still actually contain such item so long as there is no measurable effect as a result thereof.
As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.
Relative directional terms can sometimes be used herein to describe and claim various components of the present technology. Such terms include, without limitation, “upward,” “downward,” “horizontal,” “vertical,” etc. These terms are generally not intended to be limiting, but are used to most clearly describe and claim the various features of the technology. Where such terms must carry some limitation, they are intended to be limited to usage commonly known and understood by those of ordinary skill in the art in the context of this disclosure. In some instances, dimensional information is included in the figures. This information is intended to be exemplary only, and not limiting. In some cases, the drawings are not to scale and such dimensional information may not be accurately translated throughout the figures.
As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.
Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually.
This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.
The present technology relates generally to systems for modifying flooring structures to enable installation of so-called “barrier-free” or “curbless” showers in areas having traditional subfloor construction.
The present technology thus provides systems and methods by which recesses can be formed in conventional subfloor structures to allow shower tray panels to be installed with upper surfaces substantially level with the surrounding subfloor surface. This can allow installation of curbless or barrier-free showers with shower tray panels that are well supported to withstand the forces applied to such panels during ordinary use of the shower installation. The following discussion will focus on aspects of the technology utilized to remove or modify existing subfloor structures. It is to be understood, however, that the present technology can be utilized from the initial stages of building construction such that removal of any subfloor is not necessary: in other words, the present technology can be installed while or before the surrounding subfloor is installed.
As shown in
The sizing and spacing of these various components is carefully configured to ensure that upper surfaces of the shower tray panel 16 and the adjoining or primary subfloor panel 14 are substantially or nearly the same elevation. This can allow seamless installation of a flooring product (e.g., tile or stone or vinyl, etc.) above and across (e.g., spanning) each of the subfloor panel and the shower tray panel without any variances in height of the flooring product.
In some embodiments, for example, in the case of bracket 12a (and brackets 12f and 12h discussed below), the brackets are configured to be free-floating, unsupported by any adjoining structure such as a floor joist, sill plate or the like. These support brackets can be used in locations where a surrounding subfloor panel terminates near a floor joist, but not near enough to support the end of the surrounding subfloor panel with the joist. This can be advantageous in locations where it may, for example, be undesirable or impractical to remove enough adjoining subfloor to reveal or gain access to a floor support or joist near this joint between surrounding subfloor panels and shower tray panels. To account for this lack of direct support at these locations, support brackets 12a, 12f and 12h can be provided with reinforcing structure 22 to limit or prevent downward or hinging movement of the support shelf 26 (and thus recessed subfloor panel 14a).
While the reinforcing structure 22 can take a variety of forms, in the example shown, the reinforcement comprises a thickened portion adjoining the support shelf, the thickened portion including a laterally and upwardly extending opposing leg 24 that transfers the load received by support shelf 26 upwardly into the lower surface of subfloor panel 14. As the edge of the subfloor panel is not as susceptible to twisting as the support bracket might otherwise be to bending, this opposing leg 24 limits bending or deformation of the support bracket in response to loading on the support shelf.
While the reinforcing structure 22 is shown in some views as a solid piece, it is to be understood that an empty space or void can be present between the opposing leg 24 and the vertical leg 25. Other or additional reinforcing structures can also be utilized, where desired.
In another example, not shown in detail in the figures, legs B-C can be hinged relative to one another, and leg “C” can be formed to include telescoping features. Adjustment of the length of the telescoping features can achieve adjustment of the height of leg “B.”
In these examples, support bracket 12j can include a variable-use configuration: in the example of
While the support bracket 12j is shown with one or more legs formed within the concrete subfloor, the bracket can readily be reconfigured to provide a mounting interface that can allow the bracket to be secured to the concrete within the recess in a variety of manners (e.g., threaded fasteners and/or adhesives, etc.).
A lengthwise-adjustable spanning brace 50 can be disposed between the at least two floor supports 18a, 18b. The spanning brace engages on opposing ends the lateral, vertical side walls 18a′, 18b′ of the floor supports in such a manner that vertical loads experienced by the spanning brace (e.g., by the recessed subfloor panel 14a supported by the spanning brace) are transferred laterally to the floor supports. A recessed subfloor panel 14a can be supported atop the spanning brace at a lower elevation than the adjacent, primary subfloor 14.
The recessed subfloor panel 14a can take a variety of forms, but is often formed from the same material as is the surrounding primary subfloor 14. Generally, the recessed subfloor panel will include a height or thickness equal to a height of the surrounding primary subfloor. Thus, an upper surface of a ¾ inch recessed subfloor panel will be positioned ¾ of an inch below the upper surface of a ¾ inch primary subfloor. Generally the recessed subfloor panel will include a width equal to or smaller than the span distance “D” between two floor supports 18a, 18b.
In the example shown, primary subfloor 14 extends over the leftmost floor support or joist 18a and terminates above the bay 102. Note that the view shown in
In the example shown, the spanning brace 50 includes one or more endcaps 42, 44 that can be interchangeably coupleable to the ends of the spanning brace. Endcap 42 can include an opening 62 (
In the embodiment shown in
In the example shown, the spanning brace 50 can include an inner arm 56 that can be slideable within an outer arm 54. A series of openings or holes 66 can be formed in each of the inner and outer arms through which pins 68 can be fitted. The inner and outer arms can be adjusted to a macro length just short of span distance “D” (sufficiently short of engaging the sidewalls so that fasteners 64, where used, do not engage the sidewalls 18a′, 18b′). Once this macro length adjustment is achieved, the pins can be fitted in the openings to fix the outer and inner arms relative to one another. A threaded rod 70 can be rotatably attached to inner arm 56 such that rotation of the threaded rod causes the overall length of the inner arm to be adjusted. A nut or other engagement feature 72 can be fixed relative to the threaded rod. Adjustment of the nut causes an overall length of the spanning brace to be adjusted on a micro scale.
In use, the macro length of the spanning brace 50 can be adjusted and one or more ends of the spanning brace can be positioned near one or both sidewalls 18a′, 18b′. Once so positioned, nut 72 can be rotated to adjust the micro length of the spanning brace, which in turn forces cleats 64 securely into one or both of the sidewalls of the floor supports 18a, 18b. As the nut can be accessed from above through a relatively thin space or opening, the spanning brace can be installed and secured even in applications in which the space between a rightmost end of the primary subfloor 14 and the rightmost floor support 18b (
In addition to the endcap 42 having fasteners associated therewith, the system can also include one or more lateral braces 12k, 12m, etc. that can be coupleable to the lateral, vertical sides 18a′, 18b′ of the floor supports 18a, 19a. The lateral braces can cooperate with ends of the spanning brace 50 to secure the spanning brace relative to the floor supports. Lateral brace 12m can typically be used when the lateral, vertical sides of the floor supports can be relatively easily accessed, so that the lateral brace can be easily fastened into the sides of the floor supports using known screws, bolts, adhesives, etc.
As best shown in
A vertical stop 80 can optionally be formed on the upper portion of the lateral brace 12m to serve as an aid in properly aligning the brace with the upper portion of the floor support 18a, 18b. This vertical stop can be formed very thin, on the order of 1/16 of an inch, as it need not carry a great deal of load—it need only support the lateral brace in position prior to fixing the lateral brace to the floor support. Forming the vertical stop with a very thin profile can limit or prevent the vertical stop from significantly interfering with a height of a tile or other structure installed above the vertical stop. This vertical stop can also be included on bracket or brace 12k (
In one embodiment, the alignment tool 90 can include an extension 108 that includes a thickness “h.” This extension can be sized such that it easily and snugly fits within the receiving channel 20 in the lateral brace 12m created between horizontal arms 76 and 78. Thus, an installer can insert one or more alignment tools in this channel or gap and it will be temporarily held therein. The installer can then simply position the upper shelf support surface 104 upon the top of the floor support 18 and the lateral brace is automatically positioned correctly relative to the floor support. The installer can then couple the lateral brace to the floor support, after which the alignment tool can be easily slid within the lateral brace to an alternate position, or removed from the lateral brace. The alignment tool can be discarded or reused after use, as desired.
In the embodiments shown, the recessed subfloor panel 14a is carried directly atop the spanning brace 50. In some embodiments, however, the spanning brace can carry additional structure, such as leveling blocks or spacing blocks (analogous to that shown at 46 in
The present system also includes an end bracket or brace 12k that is generally intended to provide support to ends of subfloor members (either recessed or primary) beneath which no floor support is available. This can be the case in both the situation in which the unsupported end of the subfloor runs parallel to the floor supports, as shown in
As shown in more detail in
The end bracket or brace 12p can be coupled atop the spanning brace 50 (or any other brace or support structure) in a number of manners: it can be mechanically fastened atop the brace (e.g. using bolts, screws, adhesive, etc.), or it can be welded or otherwise formed integrally with the spanning brace during manufacture, etc.
This aspect of the technology can be advantageous when it is desirable or necessary to lower a drain component even further than is possible by using recessed subfloor panel 14a as a support for the drain component. For example, as shown in
In addition to the structural features discussed above, the present technology can also provide numerous methods of manufacturing, assembling, and using support brackets and braces; methods of installing floor installations; and methods of configuring floor installations.
The present support brackets can be formed from a variety of suitable materials, including, without limitation, extruded aluminum, steel, galvanized steel, etc. While not shown in detail in the figures, varying spacers or liners can be added between the subfloor panels and the support brackets (or between the subfloor panels and the shower tray panels) to adjust a height of the various panels.
The technology above is relatively easily installed in and around existing subfloors, even when access to the subfloors from below is not possible. Thus, portions of the subfloor panels can be removed from atop, the support bracketry can be installed from atop. After installation of these components, a shower tray panel or a mortar bed (neither shown) can be installed from atop, in the usual fashion. While not all of the support brackets shown may be necessary for any given installation, multiple support brackets can be provided in a kit to installers so that each bracket necessary for any particular installation is available to the installers. This can be particularly important in that the installer may not know which type of bracketry is necessary until he or she removes the subfloor panels.
It is to be understood that the above-referenced arrangements are illustrative of the application of the principles of the present technology. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present technology as set forth in the examples.
This is a continuation of U.S. patent application Ser. No. 16/507,421, filed Jul. 10, 2019, which claimed priority of and to U.S. Provisional Patent Application Ser. No. 62/696,730, filed Jul. 11, 2018, and U.S. Provisional Patent Application Ser. No. 62/849,632, filed May 17, 2019, all of which are hereby incorporated herein by reference in their entirety.
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| Number | Date | Country | |
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| Parent | 16507421 | Jul 2019 | US |
| Child | 17474657 | US |
